Multi-functional body armor

ABSTRACT

A flexible, multi-functional, multi-ply material mix and device, capable of providing ballistic protection are herein presented. The device and material herein presented provide multiple electronic and ballistic functionality integrated into a soft body armor that is lighter in weight and more comfortable to wear than previously available alternatives.

RELATED APPLICATIONS

This is a Divisional Application of U.S. application Ser. No. 13/322,292filed Nov. 23, 2011 and claims the benefit of the filing date of U.S.Provisional Application No. 61/316,426 filed on Mar. 23, 2010, theentire contents of which are incorporated by reference hereto.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The disclosed subject matter relates to ballistic protection formilitary personnel. More particularly, the disclosed subject matterrelates to a body armor made of integrated, multi-functional componentsdesigned to reduce the overall weight while increasing agility anddurability; and to a flexible, multi-functional, multi-ply material mixcapable of providing ballistic protection.

2. Brief Description of Related Art

Current soldier body armors are made of multiple layers of ballisticfabric, such as KEVLAR® brand fabric, that protect the torso from pistolshots. The addition of ceramic ballistic plates into pockets in the softarmor front, back and sides provides protection to the torso from highvelocity rifle ammunition. However, such body armor may be unavoidablycumbersome, weighing up to 30 lbs when fully fitted with the ballisticplates. Adding batteries, cabling, radios, computers, GPS, and sundryother electronic devices to such a soldier system would add a furtherweight burden and may add to the cumbersome nature of a soldier'sequipage.

SUMMARY OF THE INVENTION

A need exists, therefore, for improved ballistic protection and for abody armor system having layers of flexible materials that provideelectronic and ballistic functionality integrated into a soft body armorsolution.

In one embodiment, the disclosed subject matter relates to a flexible,multi-functional body armor device comprising an outer cover materialfacing a threat side, an inner cover material facing a skin of a user,the inner cover material being peripherally fastened to the outer covermaterial so as to form an inner compartment, non-conductive flexibleballistic outer layer disposed within, the inner compartment, thenon-conductive flexible ballistic outer layer having a plurality ofconductive ballistic antenna fibers weaved therein and at least onesmart connector operatively connected to the plurality of conductiveballistic antenna fibers.

In another embodiment, the disclosed subject matter relates to aflexible, multi-functional, multi-ply material mix capable of providingballistic protection, the flexible, multi-functional, multi-ply materialmix having a first layer with antenna fibers weaved therein, a secondlayer of insulating fibers, the first layer overlaying the second layer.A third layer of ground plane EMI shield fibers, the second layeroverlaying the third layer. A fourth layer of flexible electronics andhybrid power storage, the third layer overlaying the fourth layer. Afifth layer of insulating fibers, the fourth layer overlaying the fifthlayer. A sixth layer of power and data distribution fibers, the fifthlayer overlaying the sixth layer. A seventh layer of insulating fibers,the sixth layer overlaying the seventh layer. An eighth layer of groundplane EMI shield plies, the seventh layer overlaying the eighth layer. Aninth layer of ballistic fibers, the eighth layer overlaying the ninthlayer and a tenth layer of thermal electric generator fibers, the ninthlayer overlaying the tenth layer.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will be better understood from the detailed descriptiongiven below and by reference to the attached drawings in which:

FIG. 1 is a cross-sectional view of the multi-ply material mix;

FIG. 2 is a schematical exploded view of a ballistic vest;

FIG. 3 a is a frontal view of a full body armor; and

FIG. 3 b is a dorsal view of a full body armor.

DETAILED DESCRIPTION OF THE INVENTION

Current soldier equipage is federated, with individual stand-alonecomponents. This federated architecture results in duplication ofsubcomponents, inefficiencies and added weight. A particular concern isthe proliferation of electronic systems that have to be carried by themodern war fighter, each with batteries that are usually different indesign and function, resulting in a significant weight burden in sparebatteries alone.

Referring to FIG. 1, a preferred arrangement of the multi-ply materialmix 100 is shown. The multi-ply material mix 100 has a threat side whichis closest to the outer plies 105, and a skin side, which is farthestfrom the outer plies 105. The outer plies 105 can be made ofnon-conductive, flexible ballistic fibers 105 a. Such fibers 105 a caninclude, but are not limited to, KEVLAR® brand fibers, DYNEEMA® brandfibers, and various ultrahigh molecular weight polyethylene (UHMW-PE)fibers, including, but not limited to, TENSYLON® brand fibers. Inaddition to the preceding sample fibers, the outer plies 105 can alsoinclude Carbon Nano-Tube (CNT) fibers.

The outer plies 105 can also include conductive ballistic fibers 105 bweaved therein. It is preferred that these conductive ballistic fibers105 b are weaved in such a way as to be closest to the threat side ofthe multi-ply material mix 100. Such arrangement allows these conductiveballistic fibers 105 b to provide antennae reception and transmissioncapabilities. The conductive ballistic fibers 105 b can have multiplearrangements within, the outer plies 105. For instance, in oneembodiment the conductive ballistic fibers 105 b can be spread equallythroughout the surface area of the outer plies 105, while in otherembodiments the conductive ballistic fibers 105 b can be localizedwithin certain regions of the outer plies 105, such as areas coveringthe shoulders and neckline of a garment such as, but not limited to, avest.

Below the outer plies 105, toward the skin side, the multi-ply materialmix 100 can include at least one layer of insulator plies HO. Theseinsulator plies 110 can be made using non-conductive ballistic fibers,which can include, but are not limited to, KEVLAR® brand fibers.DYNEEMA® brand fibers and TENSYLON® brand fibers. The insulator plies110 can provide additional ballistic protection to a user. Furthermore,the arrangement of the insulator plies 110, within the multi-plymaterial mix 100 can vary. For instance, in one embodiment there can bea single layer of insulator plies 110, while in other embodiments theremay be two or more layers of insulator plies 110, thereby providingincreased ballistic protection to a user.

Below the layer of insulator plies 110, toward the skin side, themulti-ply material mix 100 can include a layer of shield plies 115. Theshield plies 115 functions as an EMI shield layer and can be made ofconductive ballistic materials, including, but not limited to, CNTfibers. In some embodiments the multi-ply material mix 100 can have asingle layer of shield plies 115, while in other embodiments themulti-ply material mix 100 can have two or more layers of shield plies115.

Below the layer of shield plies 415, toward the skin side, the multi-plymaterial mix 100 can include an electronics and power storage layer 120.The electronics and power storage layer 120 can be made from a number ofavailable flexible electronics. These applications include, but are notlimited to RF electronics, general purpose processing electronics andpower management electronics.

Below the layer of electronics and power storage 120, toward the skinside, the multi-ply material mix 100 can include a layer of power anddata distribution plies 125. The power and data distribution plies 125can be made of conductive ballistic materials, including but not limitedto, TENSYLON® brand fiber and CNT fibers.

Below the layer of power and data distribution plies 125, toward theskin side, the multi-ply material mix 100 can include a layer of thermalelectric generator plies 130. The layer of thermal electric generatorplies 130 can be made of a mixture of both conductive ballistic andnon-conductive ballistic fibers. The conductive ballistic fibers caninclude, but are not limited to, CNT fibers, while the non-conductiveballistic fibers can include, but are not limited to, KEVLAR® brandfibers, DYNEEMA® brand fibers and TENSYLON® brand fibers. Further, theratio of conductive ballistic fibers to non-conductive ballistic fibersin the layer of the thermal electric generator plies 130 can vary.

The multi-ply material mix 100 can be used in the construction of bodyarmor, such as the armored vest depicted in FIG. 2 and/or the full bodyarmor depicted in FIG. 3. However, the multi-ply material mix 100 is notlimited in its use to such applications. In fact, the multi-ply materialmix 100 can be used in the construction of other equipment including,but not limited to, tents, clothing, etc. Further, the ballisticproperties of the multi-ply material mix 100 can be strengthened byadding additional ballistic plies 140 as desired.

The several layers of the multi-ply material mix 100 can be heldtogether through different fastening mechanisms, including, but notlimited to stitching and gluing.

Referring to FIG. 2, a ballistic vest 200 embodiment of the multi-plymaterial mix is shown. In this embodiment, the multi-ply material mix(not shown) can be easily incorporated into a ballistic vest 200, whichin one embodiment can be shaped like a human torso, having a front sideand a back side. The ballistic vest 200 includes an outer cover 205 andan inner cover (not shown), which are peripherally sewn to create aninner compartment (not shown) in which the multi-ply material mix (notshown) is disposed. Accordingly, the ballistic vest 200 is capable ofproviding a user ballistic protection, while at the same time providinga number of integrated capabilities.

For instance, the ballistic vest is capable of providing integratedantennae transmission and reception capabilities by incorporatingantennae fibers 210. In one embodiment, the antennae fibers 210 can bemade out of conductive ballistic fibers located en the outer plies (notshown) multi-ply material mix (not shown), the antennae fibers 210 canbe positioned near the shoulder area of the ballistic vest 200, wherethey can most effectively provide the user, antennae transmission andreception capabilities. In other embodiments, the antennae fibers 210can be positioned around the neck line of the ballistic vest, or wraparound the shoulder blade area of the ballistic vest 200. Preferably,the antennae fibers 210 are placed directly below the outer cover 205,so as to improve performance. Because the multi-ply material mix (notshown) incorporates a number ballistic fibers, the ballistic vest 200 iscapable of providing 360® ballistic protection.

The arrangement of the fibers in the multi-ply mix can modified to meetthe requirements of different applications. For instance, in the vest200 embodiment, additional CNT fibers 220, which provide increasedballistic protection, can be placed to protect sensitive areas, such asthose covering the vital organs of user.

The ballistic vest 200 can also be equipped with a region of power anddata distribution fibers 230. These power and data distribution fibers230 can be both conductive ballistic and non-conductive ballisticfibers. Additionally, the power and data distribution fibers 230 can bearranged virtually anywhere on the ballistic vest 200, and are thereforenot restricted in placement to any given region within the ballisticvest 200. In other embodiments, additional ballistic protection can alsobe provided by incorporating non-conductive ballistic fibers tot shown).These non-conductive ballistic fibers can include, but are not limitedto, KEVLAR® brand fibers, DYNEEMA® brand fibers and TENSYLON® brandfibers.

The ballistic vest 200 is also capable of harnessing and storing energyin a power storage unit 240. For instance, in one embodiment conductiveballistic fibers can channel harnessed energy (i.e. thermal energy) forstorage in a power storage unit 240. Power and data distribution fibers230 can then be used to access the power storage unit 240 and make thispower available to external devices via smart connectors 270. In someembodiments, the power storage unit 240 may be capable to store up to 96hours of usable power.

As was noted above, data and power transfer to and from the ballisticvest 200 can be achieved by incorporating smart connectors 270,including, but not limited to, SNAP Net® brand connectors. These smartconnectors 270 come in a variety of snap geometries and therefore allowfor the integration of a variety of applications, including, but notlimited to, USB devices, RF antennas and various other electronicdevices. Further, the placement of the smart connectors 270 is notlimited to the shoulder area, as the smart connectors 270 may be placedvirtually anywhere on the ballistic vest 200.

Additionally, the ability to transmit power from the power storage unit240 via the power and data distribution fibers 230 allows the ballisticvest 200 to be fitted with additional electronic devices, including butnot limited to, small single-board computers 290 such as GUMSTIX® brandcomputers and SAINT® brand handheld devices 260.

Further, the ballistic vest 200 can be equipped with any desired numberof storage compartments 250. These storage compartments 250 can beconstructed out of the same materials as the ballistic vest 200, andtherefore provide a convenient means to store and transport cargowithout compromising safety. The cargo can vary depending on theapplication and may include land mobile radio units 280, handhelddevices 260, single-board computers 290, etc. Additionally, the storagecompartments 250 can be placed in any desired location on the ballisticvest 200.

The ballistic vest 200 can also be equipped with an EMI shield 293. TheEMI shield 293 can be made of ballistic fibers, including, but notlimited to, CNT fibers. These ballistic fibers provide a great degree offlexibility and exhibit reduced weight, compared to traditional metalEMI shield applications. Accordingly, the ballistic vest 200 can befitted with an EMI shield 293 throughout the vest, thereby providing360° magnetic radiation protection, without increasing ballistic vest200 weight and while retaining ballistic vest 200 flexibility. In otherembodiments, additional layers of EMI shield 293 can be disposed inareas of the ballistic vest 200 that protect vital organs. For example,in one embodiment, additional EMI shield 293 layers can be disposed inthe frontal section of the ballistic vest 200, while in otherembodiments additional EMI shield 293 layers can be disposed in thedorsal section of the ballistic vest 200.

The ballistic vest 200 can also be fitted with a layer of flexibleelectronics 295. The flexible electronics 295 layer can be distributedthrough the ballistic vest 200. The flexible electronics 295, caninclude, but are not limited to RF electronics, general purposeprocessing and power management electronics.

Referring to FIGS. 3 a and 3 b, a full body ballistic armor 300embodiment of the multi-ply material mix is shown. That is the inaddition to protecting the anterior 310 and posterior 320 regions of thetorso, the multi-ply material mix (not shown) can be use to provide fullbody ballistic protection including, the head 330, upper limbs 340 andlower limbs 350. Because of the high flexibility and reduced weight(compared to traditional federated ballistic materials) the bull bodyballistic armor 300 provides improved mobility without compromisingthreat protection.

It is to be understood, that the above-described arrangements areintended solely to illustrate the application of the principles of thedisclosed subject matter. Numerous modifications and alternativearrangements may be devised by those skilled in the art withoutdeparting from the spirit and scope of the disclosed subject matter inthe present Application. Accordingly, the appended claims are intendedto cover such modifications and alternative arrangements. Thus, whilethe disclosed subject matter of the present Application has beendescribed above with particularity and detail in connection with what ispresently deemed to be the most practical and preferred embodiments, itwill be apparent to those skilled in the art that numerousmodifications, including, but not limited to, variations in size,materials, shape, form, function and manner of operation, assembly anduse may be made without departing from the principles and concepts setforth herein.

What is claimed is:
 1. A flexible, multi-functional body armor devicecomprising: an outer cover material facing a threat side; an inner covermaterial facing a skin of a user, the inner cover material beingperipherally fastened to the outer cover material so as to form an innercompartment; a non-conductive flexible ballistic outer layer disposedwithin the inner compartment, the non-conductive flexible ballisticouter layer having a plurality of conductive ballistic antenna fiberscomprised on Carbon Nano-Tube (CNT) fibers weaved therein; and at leastone smart connector operatively connected to the plurality of conductiveballistic antenna fibers.
 2. The flexible, multi-functional body armordevice of claim wherein the non-conductive flexible ballistic outerlayer is disposed immediately below the outer cover material.
 3. Theflexible, multi-functional body armor device of claim 2, furthercomprising at least one non-conductive ballistic layer.
 4. The flexible,multi-functional body armor device of claim 3, further comprising atleast one ground plane EMI shield ballistic layer made of ballisticmaterial.
 5. The flexible, multi-functional body armor device of claim4, further comprising at least one power and data distribution layercomprised of both conductive and non-conductive ballistic fibers weavedtherein.
 6. The flexible, multi-functional body armor device of claim 5,further comprising at least one thermal electric generating layer. 7.The flexible, multi-functional body armor device of claim 6, furthercomprising at least one layer of flexible electronics.
 8. The flexible,multi-functional body armor device of claim 6, wherein the at least onethermal electric generating layer is made of a mixture of non-conductiveballistic materials and conductive ballistic materials.
 9. The flexible,multi-functional body armor device of claim 7, wherein the at least onelayer of flexible electronics can be selected from the group consistingof RF electronics, general purpose processing electronics and powermanagement electronics.
 10. A flexible, multi-functional body armordevice comprising: an outer cover material facing a threat side; aninner cover material facing a skin of a user, the inner cover materialbeing peripherally fastened to the outer cover material so as to form aninner compartment; a non-conductive flexible ballistic outer layerdisposed immediately below the outer cover material within the innercompartment, the non-conductive flexible ballistic outer layer having aplurality of conductive ballistic antenna fibers weaved therein; atleast one smart connector operatively connected to the plurality ofconductive ballistic antenna fibers; at least one ground plane EMIshield ballistic layer made of a ballistic material; and at least onepower and data distribution layer comprised of both conductive andnon-conductive ballistic fibers weaved therein.
 11. The flexible,multi-functional body armor device of claim 10, further comprising atleast one thermal electric generating layer.
 12. The flexible,multi-functional body armor device of claim 11, further comprising atleast one layer of flexible electronics.